GPI 314 – How long does it take to get your machines fixed and why?

Ask your maintenance department at what point they know when a production machine is down (not operating).  How does anyone know that your machines need repair?  How quickly are problems spotted, reported and resolved?  Who’s responsible or is your current reporting process faulty?

Find out what causes your maintenance department to get involved once a revenue producing machine is down.  Here are a few questions to ask:

Procedures for machines that require maintenance:

• How long does it take from the moment the machine goes down until maintenance is notified? Ten minutes?  Thirty minutes?  One hour?  Next shift? Next day?  Know this average time lapsed immediately.
• Who is responsible to report machine downtime?
• At what point does a machine that is down get reported? Is there a time frame or limit? (i.e. within five minutes, by the end of the shift, as soon as the machine is needed).
• Is the reporting requirement for a down machine listed in the job description of the operator?
• Is it part of the operator’s job description to notify the production supervisor when bad parts are being made? (Sign of machine problems).
• Is it part of the operator’s job description to notify the production supervisor when his assigned machine is making odd irregular noises or when there are problems operating the machine?
• How quickly are machines repaired? What is expected of the maintenance department?
• Are maintenance personnel properly trained on all of the machines by the manufacturers?
• Are maintenance personnel sent off site to attend training sessions at the manufacturer’s facilities?

Make employees responsible for reporting machine problems.  If you do not know any of this procedure, ask. Keep probing and you will find gaps.  Many times, procedures are written but not taught, nor are they repeated to stress the importance of keeping all machines operating.  Make sure the onus is put on the employee because the production supervisor cannot cover all of the departments.  He must depend upon good operators.